New Generation of Reifenhäuser Ultra Die Heads

Global leader in sustainable packaging, Smurfit Westrock, hosted a “Barrier Day Open House” on April 15 at its production facility in Ibi (Alicante), Spain, in collaboration with machine manufacturer Reifenhäuser Blown Film. A large international group of customers and industry experts gathered to experience the latest generation of Reifenhäuser EVO Ultra Die Heads in a live customer operation. 

The highlight was the output of over 1,000 kg/h for barrier applications, delivering films with outstanding properties, including a profile accuracy of better than ±3 % 2σ at a thickness of 70 μm. To ensure the film’s outstanding tolerance even at extreme throughput rates, the line combines the new EVO Ultra Die Head with the perfectly matched internal bubble cooling system EVO Cool and market-leading Kdesign cooling ring technology. In addition, Smurfit utilizes the proven Reifenhäuser Ultra Flat System, which ensures perfectly flat film for easy further processing. 

“The results of the new EVO 7-layer blown film line with the EVO Ultra Die 7 have exceeded our expectations,” says Pascual Martínez Pérez, Managing Director of Smurfit Westrock Spain. “No other supplier achieves the nominal outputs we have achieved.”

With the new line, Smurfit Westrock now operates a total of three Reifenhäuser blown film lines at this location, further expanding its capacity. At the same time, the new generation of die heads sets new benchmarks in productivity without compromising quality or stability. 

Bernd Reifenhäuser, CEO of the Reifenhäuser Group, adds: “The real competitive edge is about more than technology. It’s what we’ve built together over seven years – trust, partnership, and measurable results. Every major step we’ve taken in this partnership started with one question: What creates the greatest value for Smurfit Westrock? Today’s demonstration is a perfect example.” 

On the new blown film line, put into production at the beginning of 2026, Smurfit Westrock produces seven-layer films with barrier properties which are used, among other applications, for so-called bag-in-box packaging. This type of packaging consists of a sturdy cardboard box containing a plastic bag filled with liquid. A spout allows the beverage to be dispensed and prevents oxygen from entering – just like the 100% oxygen barrier of the plastic film. 

In addition to maximum performance and first-class film quality, the new production line offers a high degree of flexibility. If required, production can be quickly switched from seven-layer film to five- or three-layer film. Despite the large geometry and high volume of the die head, fast changeover times are ensured thanks to its particularly maintenance-friendly design. 

The live demonstration was accompanied by a series of expert presentations on the production of barrier films and packaging. The presentations addressed the specific challenges of barrier applications and highlighted the advantages of the new Reifenhäuser Ultra Die Head generation.